Obsolete Toshiba PLC Replaced with Modern Siemens Controller for Industrial Oven
Sector:
General Manufacturing
Type:
Obsolecence Upgrade, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl replaced an end-of-life Toshiba PLC controlling an industrial electric oven with a modern Siemens S7-series controller, including a full software rewrite and on-site commissioning support.
Challenge
A Toshiba PLC controlling an electric oven on a production line had reached the end of its serviceable life. The hardware was no longer available to purchase, no manufacturer support existed, and no original documentation for the system could be located.
The programming environment required to interrogate or modify the existing Toshiba controller was also unavailable, meaning the only reference material for the control logic was a ladder diagram provided in PDF form.
Solution
DelaControl selected a Siemens S7-series PLC as the replacement platform — a current, actively supported product with no near-term obsolescence risk. The existing ladder logic, supplied as a PDF, was used as the basis for a complete software rewrite in Siemens TIA Portal, developed in line with DelaControl's in-house software design standards to ensure the result is maintainable and clearly structured.
Pre-delivery testing was carried out at DelaControl's Bristol facility using I/O simulation equipment to validate correct operation before the rack was shipped. A commissioning engineer attended site to remove the old Toshiba rack, install the new Siemens controller, and remain with the system to confirm satisfactory oven operation.
Key Facts
• Replacement platform: Siemens S7-series PLC
• I/O modules supplied: 5 × DI 16-channel (230 VAC), 1 × DQ 32-channel (24 VDC), 4 × DQ 8-channel relay (230 VAC/5A)
• 1 × ET 200MP IM 155-5 PN BA interface module included
• Full control logic rewrite in Siemens TIA Portal from ladder diagram source
• Pre-delivery I/O simulation testing carried out at DelaControl facility
• On-site commissioning: 1 engineer, up to 3 days